Tubular member with thermal sleeve liner

Abstract

A tubular fluid flow device of varying outside dimensions adapted for use in a high pressure, rapidly cycling temperature environment, an isolation ball valve, a ball valve isolation method and a catalyst transfer method. The flow device 10 can have a tubular member 12 having at least one locus 14, 16 of non-uniform outside dimension and an axial flow passage 20 with a uniform inside diameter between opposite end connection elements. A thermal sleeve liner 22 can be disposed about the axial flow passage in a bore 24 formed in the tubular member, wherein the sleeve comprises an outer surface having a thermal barrier coating 26 . A pressure-relief passage 28 is provided in fluid communication between the axial flow passage and an interface between an exterior surface of the thermal sleeve liner and an inner surface of the bore.

The invention claimed is: 
     
       1. A tubular fluid flow device of varying outside dimensions for use in a rapidly cycling temperature environment, comprising:
 a tubular member ( 10 ) having at least one locus of non-uniform outside dimension ( 14 ,  16 ) and an axial flow passage ( 20 ) with a uniform inside diameter between opposite end connection elements ( 16 ); 
 a thermal sleeve liner ( 22 ) disposed about the axial flow passage in a bore ( 24 ) formed in the tubular member; 
 a thermal barrier coating ( 26 ) disposed on an exterior surface of the thermal sleeve liner ( 22 ) located at an interface between and in direct contact with the exterior surface of the thermal sleeve liner and an inner surface of the bore; and 
 a pressure-relief passage ( 28 ) in fluid communication with the interface between the exterior surface of the thermal sleeve liner and the inner surface of the bore. 
 
     
     
       2. An isolation ball valve, comprising a pair of opposing ball valve members ( 102 A,  102 B) connected on either end of an end connector ( 104 ), wherein the end connector comprises the tubular fluid flow device of  claim 1 . 
     
     
       3. The isolation ball valve of  claim 2  wherein the tubular member has seat recesses ( 106 ) to retain seals ( 108 ) adjacent the ball valve members. 
     
     
       4. The isolation ball valve of  claim 3  wherein the pressure-relief passage comprises annular passages formed by an axial offset between an end of the thermal sleeve liner and the respective seals. 
     
     
       5. The tubular fluid flow device of  claim 1  comprising flanged end connections and wherein the tubular member has a uniform outside diameter between the flanged end connections. 
     
     
       6. The tubular fluid flow device of  claim 1  wherein the thermal sleeve liner is press fitted in the bore, shrink fitted in the bore, welded in the bore, or a combination thereof. 
     
     
       7. The tubular fluid flow device of  claim 1  wherein the thermal barrier coating comprises ceramic. 
     
     
       8. The tubular fluid flow device of  claim 1  wherein the thermal barrier coating comprises zirconia. 
     
     
       9. The tubular fluid flow device of  claim 1  wherein the thermal barrier coating comprises yttria-stabilized zirconia. 
     
     
       10. The tubular fluid flow device of  claim 1  wherein the thermal sleeve liner comprises a hardened, heat-resistant material. 
     
     
       11. The tubular fluid flow device of  claim 1 , further comprising a bond layer ( 30 ) between and in direct contact with the exterior surface of the thermal sleeve liner and the thermal barrier coating such that the thermal barrier coating ( 26 ) is disposed between and in direct contact with the bond layer of the thermal sleeve liner and an inner surface of the bore. 
     
     
       12. A ball valve isolation method for a high pressure, rapidly cycling temperature service, comprising:
 installing an isolation ball valve ( 204 ,  208 ) in a line ( 202 ) comprising a pair of opposing ball valve members ( 102 A,  102 B) connected on either end of an end connector ( 104 ) comprising a tubular fluid flow device; and 
 cycling operation of the isolation ball valve in service at a temperature swing of at least 250° C. at a frequency of at least one cycle per week; 
 wherein the tubular fluid flow device comprises a tubular member ( 10 ) having at least one locus of non-uniform outside dimension ( 14 ,  16 ) and an axial flow passage ( 20 ) with a uniform inside diameter between opposite end connection elements ( 16 ); 
 a thermal sleeve liner ( 22 ) disposed about the axial flow passage in a bore ( 24 ) formed in the tubular member, wherein the sleeve comprises an outer surface having a thermal barrier coating ( 26 ); and 
 a pressure-relief passage ( 28 ) in fluid communication with an interface between an exterior surface of the thermal sleeve liner and an inner surface of the bore, and 
 wherein the thermal sleeve liner is effective to inhibit thermal fatigue stress cracking in the end connector. 
 
     
     
       13. The ball valve isolation method of  claim 12  wherein alternating thermal stresses developed in the tubular member are less than 52 ksi (360 MPa). 
     
     
       14. The ball valve isolation method of  claim 12  wherein peak alternating thermal stresses developed in the tubular member are sufficiently low to achieve a design life of at least 30,000 cycles. 
     
     
       15. The ball valve isolation method of  claim 12  further comprising servicing the isolation ball valve by removing and replacing the thermal sleeve liner. 
     
     
       16. A method for the transfer of catalyst from a reactor, comprising:
 positioning an isolation ball valve ( 100 A to  100 C,  100 F to  100 G) in a conduit ( 202 ,  214 ) exiting the reactor ( 200 ,  206 ); and 
 cycling the isolation ball valve between an open position to transfer catalyst from the reactor and a closed position to stop the catalyst transfer, 
 wherein the isolation ball valve comprises a pair of opposing ball valve members ( 102 A,  102 B) connected on either end of an end connector ( 104 ) comprising a tubular fluid flow device comprising a tubular member ( 10 ) having at least one locus of non-uniform outside dimension ( 14 ,  16 ) and an axial flow passage ( 20 ) with a uniform inside diameter between opposite end connection elements ( 16 ); 
 a thermal sleeve liner ( 22 ) disposed about the axial flow passage in a bore ( 24 ) formed in the tubular member; 
 a thermal barrier coating ( 26 ) disposed on an exterior surface of the thermal sleeve liner ( 22 ) located at an interface between and in direct contact with the exterior surface of the thermal sleeve liner and an inner surface of the bore; and 
 a pressure-relief passage ( 28 ) in fluid communication with the interface between the exterior surface of the thermal sleeve liner and the inner surface of the bore. 
 
     
     
       17. The catalyst transfer method of  claim 16  wherein alternating thermal stresses develop in the tubular member, and wherein the alternating thermal stresses developed in the tubular member are less than 52 ksi (360 MPa). 
     
     
       18. The catalyst transfer method of  claim 16  wherein peak alternating thermal stresses develop in the tubular member, and wherein the peak alternating thermal stresses developed in the tubular member are sufficiently low to achieve a design life of at least 30,000 cycles. 
     
     
       19. The catalyst transfer method of  claim 16  further comprising servicing the isolation ball valve by removing and replacing the thermal sleeve liner. 
     
     
       20. The tubular fluid flow device of  claim 1 , wherein the pressure-relief passage ( 28 ) comprises an annular passage formed by an axial offset between an end of the thermal sleeve liner and an inner recessed face adjacent the bore ( 24 ), in fluid communication with the interface between the exterior surface of the thermal sleeve liner and the inner surface of the bore.